Integrated ptsa/membrane method and system for h2s and co2 removal from biogas

ABSTRACT

Biogas containing H2S and CO2 is upgraded by removing H2S using PTSA and CO2 using two stages of gas separation membranes. The first stage permeate may optionally be used a regeneration gas stream. The second stage permeate may optionally be used a cool down gas stream. The PTSA unit includes two or more adsorbent beds each selective for water, VOCs, and H2S over CO2 and for H2S over methane.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.15/887,588, filed Feb. 2, 2018, which claims the benefit of U.S.Provisional Application No. 62/454,255, filed Feb. 3, 2017, which isbeing incorporated by reference herein in its entirety for all purposes.

BACKGROUND Field of the Invention

The present invention relates to purification of biogas, in particular,of digester gas or landfill gas using an integrated gas separationsystem including TSA and membranes.

Related Art

Biogas contains impurities of H₂S, volatile organic compounds (VOCs),water, CO₂ and air. Removal of such impurities can yield nearly puremethane for sale as natural gas. Two typical types of biogas arelandfill gas and digester gas. Landfill gas is obtained from a landfillwhere microorganisms convert waste primarily to methane and CO₂.Digesters anaerobically ferment agricultural, human waste, or otherorganic containing sources also resulting primarily in methane and CO₂.While the main constituents of biogas are methane and CO₂, they alsoinclude minor levels of water vapor, VOCs, CO₂, H₂S, and sometimessiloxanes (i.e., in landfill gas). The H₂S present in biogas, especiallyfor high H₂S levels often found in digester gas, poses an economic andtechnical challenge because the product natural gas must meetrequirements of relatively low H₂S levels in order for it to be usefulas a fuel or meet pipeline specifications. For example, while naturalgas pipelines typically require an H₂S level of 4 ppm (v/v) or less anda CO₂ level of 2% (v/v) or less, digester gas often contains CO₂ levelsof 25-45% (v/v) and relatively high H₂S levels of 100 ppm-1% (v/v).

Many technologies today are applied to upgrade digester gas including apatented (U.S. Pat. No. 7,025,803) purification system offered by AirLiquide Advanced Technologies, US. This system includes a pressure swingadsorption (PSA) unit followed by an activated carbon bed for water andVOC removal. The water and VOC-depleted gas is then fed to a two stagegas separation membrane unit for removal of CO₂. The first stage removesthe bulk of the CO₂ present in the biogas. The CO₂ rich reject stream atlow pressure from the first stage is used to regenerate the PSA unit toproduce an impurity-laden CO₂ rich reject stream containing methane(lost from the feed gas via permeation through the membranes of thefirst stage), rejected CO₂ and desorbed VOCs and water. This stream istypically routed to a thermal oxidizer for destruction of the VOCs priorto venting. The methane rich second stage permeate is also at lowpressure, so it is recycled to the suction inlet of the compressorupstream of the PSA unit. While this system has performed remarkablywell, it does not satisfactorily handle relatively high levels of H₂S,and for that reason, a separate H₂S removal system (such as SulfaTreator other treatment method) may required for raw biogas containingrelatively high H₂S levels. Inclusion of the separate H₂S removal systemadds cost and complexity to the overall system.

A key advantage of the above-described Air Liquide system for treatmentof biogas from landfills is removal by the membrane unit of a bulk ofthe O₂ in the biogas along with the CO₂. While pipeline specificationsfor O₂ may vary, a typical requirement is O₂ levels no higher than 0.2%(v/v). While biogas obtained from digesters should be O₂ free due to theanaerobic conditions of the digesters, digesters are low pressureoperations that may allow of introduction of some amounts of air. Thus,some amount of O₂ is commonly encountered in digester-derived biogas.

Another digester gas upgrading system is offered by Guild Associates,Inc. One Guild system includes a PSA system that has the ability toadsorb H₂O, H₂S and CO₂ in a single unit. A key attribute of this systemis its ability to simultaneously adsorb and desorb H₂S, water and CO₂.However, this technology is limited for feeds containing O₂ and N₂ sincethe PSA unit enriches O₂ and N₂ in the product gas, typically by afactor of about 1.7× the feed gas concentration. Thus, for a productcontaining 2000 ppm O₂ (v/v), the raw gas fed to the PSA unit is limitedto an O₂ level of only 1200 ppm (v/v). If the O₂ limit of the raw gas isexceeded, an additional process unit or units for removal of O₂ will berequired. Inclusion of an additional process unit or units for removalof O₂ adds cost and complexity to the overall system.

Other PSA systems for digester gas upgrading have been proposed.However, many of such systems typically include a pretreatment systemfor H₂S removal, thus adding cost and complexity.

Water-wash systems have been proposed for upgrading digester gas. Suchsystems include an air-stripped stream of water that is contacted over apacked bed against a rising feed stream. CO₂ present in the feed streamdissolves into the stream of water. The CO₂-laden water stream issubsequently let down in pressure and stripped with air for removal ofthe dissolved CO₂ derived from the feed stream. In water-wash system,amounts of H₂S present in the feed stream may also be removed throughdissolution in the water stream. In such a case, the regenerated streamis the stripping air plus the CO₂ and H₂S. As with the Guild system, O₂and N₂ are not removed but instead are enriched in the product stream.

Similarly to the water-wash system, amine or physical solvent basedupgrading systems have also been proposed for upgrading of biogas. Insuch systems, the solvent absorbs CO₂ and H₂S present in the feedstream, and after pressure letdown, the solvent is regenerated byreboiling the solvent to drive off the previously absorbed CO₂ and H₂S.In other words, external stripping air is not used. For physicalsolvents, the reboiling can be reduced or in some cases eliminated andpressure letdown of the rich solvent may be used alone for regeneration.However, similar to the Guild system and water-wash systems, amine orphysical solvent based systems enrich O₂ and N₂ in the product stream.

Thus, is an object to upgrade biogas, particularly digester gas, thatincludes O₂ and relatively high levels of H₂S using a system that doesnot have an unnecessarily high cost or level of complexity.

SUMMARY

There is disclosed a biogas upgrading method based upon PTSA and gasseparation membranes. The method includes the following steps. A streamof biogas is compressed with a main compressor. A PTSA feed gas streamwithdrawn from an outlet of the main compressor is fed to a PTSA unit.H₂S is removed from the PTSA feed gas stream with the PTSA unit. AnH₂S-depleted PTSA product stream is withdrawn from the PTSA unit. ThePTSA product stream is fed to a first gas separation membrane stagecomprising one or more gas separation membranes selective for CO₂ and O₂over methane. A first stage permeate stream enriched in CO₂ and O₂ anddeficient in methane compared to the PTSA product stream and a firststage retentate stream deficient in CO₂ and O₂ and enriched in methanecompared to the PTSA product stream are withdrawn from the first gasseparation membrane stage. The first stage retentate stream is fed to asecond gas separation membrane stage comprising one or more gasseparation membranes selective for CO₂ and O₂ over methane. A secondstage permeate stream enriched in CO₂ and deficient in methane comparedto the first stage retentate stream and a second stage retentate streamdeficient in CO₂ and enriched in methane compared to the first stageretentate stream are withdrawn from the second gas separation membranestage. The second stage retentate stream is a product natural gasstream. Repressurization of the beds is performed with one or more ofthe PTSA feed gas stream, the PTSA product gas stream, the first stageretentate stream, and the second stage retentate stream. The PTSA unitcomprises two or more adsorbent beds each of which is selective forwater, VOCs, and H₂S over CO₂ and for H₂S over methane. Each of saidbeds is subjected to a PTSA cycle comprising the phases of: adsorptionof water, VOCs, and H₂S from the PTSA feed gas stream; depressurization;thermal regeneration using a regeneration gas stream in which adsorbedwater, VOCs, and H₂S are desorbed; cool down using a cool down gasstream; and repressurization.

There is also disclosed a biogas upgrading system based upon PTSA andgas separation membranes, comprising: a source of raw biogas comprisingmethane, CO₂, water, VOCs, and H₂S; a main compressor including asuction inlet in fluid communication with the source and receiving astream of raw biogas from the source; a PTSA unit comprising two or moreadsorbent beds each of which is selective for water, VOCs, and H₂S overCO₂ and for H₂S over methane, the PTSA unit being in downstream fluidcommunication with the main compressor and receiving a stream of a PTSAfeed gas therefrom, the PTSA unit being adapted and configured to adsorbwater, VOCs, and H₂S from the PTSA feed gas and produce a PTSA productgas deficient in water, VOCs, and H₂S in comparison to the PTSA feedgas; a first gas separation membrane stage comprising one or more gasseparation membranes selective for CO₂ and O₂ over methane, a feed gasinlet of the first gas separation membrane stage being in downstreamfluid communication with the PTSA unit, the first gas separationmembrane stage being configured and adapted to separate the PTSA productgas into a first stage permeate gas stream and a first stage retentategas stream; a second gas separation membrane stage comprising one ormore gas separation membranes selective for CO₂ and O₂ over methane, afeed gas inlet of the second gas separation membrane stage being indownstream fluid communication with the retentate outlet of the firstgas separation membrane stage and receiving the first stage permeate gasstream therefrom, the second gas separation membrane stage being adaptedand configured to separate the first retentate gas stream into a secondpermeate gas stream and a second retentate gas stream; and a treatmentunit in downstream fluid communication with the PTSA unit so as toreceive a waste gas from the PTSA comprised of the thermal regenerationgas and water, VOCs, and H₂S, the treatment unit being adapted andconfigured to either oxidize or burn the VOCs contained in the wastegas. The PTSA unit is in fluid communication with the permeate gasoutlet of the first gas separation membrane stages so as to receive aflow of the first stage permeate gas for use as a thermal regenerationgas to thermally regenerate and desorb water, VOCs, and H₂S that wasadsorbed upon the adsorbent beds from the PTSA feed gas stream. The PTSAunit is in fluid communication with the permeate gas outlet of thesecond gas separation membrane stage so as to receive a flow of thesecond permeate gas stream for use as a cool down stream for cooling oneor more adsorbent beds after thermal regeneration thereof; and

The method and/or system may include one or more of the followingaspects:

-   -   the compressed feed gas is cooled prior to introduction to the        PTSA.    -   some or all of the second stage permeate stream is the cool down        gas stream and the cool down gas stream is received from the        PTSA unit by a suction inlet of the main compressor where it is        combined with the compressed biogas stream.    -   the second stage permeate stream is received at and compressed        by a secondary compressor and the compressed second stage        permeate stream is fed to the first gas separation stage along        with the PTSA product stream.    -   a waste gas comprised of the regeneration gas stream and the        H₂S, water, and VOCs desorbed from one or more adsorbent beds of        the PTSA unit is thermally oxidized at a thermal oxidizer.    -   the regeneration gas stream is comprised of some or all of the        first stage permeate stream which has been heated to a        temperature above the PTSA feed gas temperature.    -   a waste gas stream comprised of the regeneration gas stream and        the H₂S, water, and VOCs desorbed from one or more adsorbent        beds of the PTSA unit is thermally oxidized at a thermal        oxidizer.    -   some or all of the second stage permeate stream is the cool down        gas stream and the cool down gas stream is received from the        PTSA unit at a suction inlet of the main compressor where it is        combined with the compressed biogas stream    -   amounts of H₂S present in the PTSA feed gas stream are removing        by an H₂S removal unit prior to feeding the PTSA feed gas stream        to the PTSA unit, wherein the PTSA unit removes amounts of water        and VOCs from the PTSA feed gas stream and also amounts of the        H₂S remaining in the PTSA feed gas stream after treatment by the        H₂S removal unit.    -   the regeneration gas stream is heated to the temperature above        the PTSA feed gas temperature through heat exchange, at a heat        exchanger, with cooling oil circulating through the first        compressor.    -   some or all of the regeneration gas stream is the first stage        permeate stream.    -   a waste gas comprised of the regeneration gas stream and the        H₂S, water, and VOCs desorbed from one or more adsorbent beds of        the PTSA unit is thermally oxidized at a thermal oxidizer and        the regeneration gas stream is heated to the temperature above        the PTSA feed gas temperature through heat exchange, at a heat        exchanger, with hot gas produced in the thermal oxidizer.    -   the PTSA unit comprises first and second adsorbent beds, and the        PTSA unit cycle comprises: a first phase during which the first        bed undergoes adsorption and the second bed undergoes        depressurization and then thermal regeneration; a second phase        during which the first bed undergoes adsorption and the second        bed undergoes cool down and then repressurization; a third phase        during which the second bed undergoes adsorption and the first        bed undergoes depressurization and then thermal regeneration;        and a fourth phase during which the second bed undergoes        adsorption and the first bed undergoes cool down and then        repressurization.    -   the PTSA unit comprises first, second, and third adsorbent beds,        and the PTSA unit cycle comprises: a first phase during which        the first bed undergoes adsorption, the second bed undergoes        cool down and then repressurization, and the third bed undergoes        depressurization and then thermal regeneration; a second phase        during which the second bed undergoes adsorption, the third bed        undergoes cool down and then repressurization, and the first bed        undergoes depressurization and then thermal regeneration; and a        third phase during which the third bed undergoes adsorption, the        first bed undergoes cool down and then repressurization, and the        second bed undergoes depressurization and then thermal        regeneration.    -   the PTSA unit comprises first, second, third, and fourth        adsorbent beds, and the PTSA unit cycle comprises: a first phase        during which the first and fourth beds undergo adsorption, the        second bed undergoes cool down and then repressurization, and        the third bed undergoes depressurization and then thermal        regeneration; a second phase during which the first and second        beds undergo adsorption, the third bed undergoes cool down and        then repressurization, and the fourth bed undergoes        depressurization and then thermal regeneration; a third phase        during which the second and third beds undergo adsorption, the        fourth bed undergoes cool down and then repressurization, and        the first bed undergoes depressurization and then thermal        regeneration; and a fourth phase during which the third and        fourth beds undergo adsorption, the first bed undergoes cool        down and then repressurization, and the second bed undergoes        depressurization and then thermal regeneration.    -   the suction inlet of the main compressor is in fluid        communication with the PTSA unit so as to receive the cool down        gas stream from the PTSA unit and allow combination and        compression with the raw biogas stream.    -   a secondary compressor including a suction inlet is in fluid        communication with the PTSA unit so as to receive the cool down        gas stream from the PTSA, wherein the feed gas inlet of the        first gas separation membrane stage is in downstream fluid        communication with an outlet of the secondary compressor so as        to receive the cool down gas stream after compression by the        secondary compressor and separate a combined feed of the cool        down gas stream and the PTSA product gas into the first stage        permeate gas stream and a first stage retentate gas stream.    -   the main compressor includes an oil cooling circuit including a        heat exchanger adapted and configured to exchange heat between        the first stage permeate and oil flowing in the cooling circuit        so as to heat the first stage permeate to the temperature at        which thermal regeneration of the adsorbent beds is to take        place.    -   a H₂S removal unit is in flow communication between the main        compressor and the PTSA unit, the H₂S removal unit being adapted        and configured to remove amounts of H₂S present in the PTSA feed        gas stream prior to feeding the PTSA feed gas stream to the PTSA        unit, wherein the PTSA unit is adapted and configured to remove        amounts of water and VOCs from the PTSA feed gas stream and also        amounts of the H₂S remaining in the PTSA feed gas stream after        treatment by the H₂S removal unit.    -   a heat exchanger is adapted and configured to exchange heat        between hot gas from the treatment unit and the regeneration gas        stream so as to heat the regeneration gas stream to the        temperature above the PTSA feed gas temperature.

BRIEF DESCRIPTION OF THE DRAWINGS

For a further understanding of the nature and objects of the presentinvention, reference should be made to the following detaileddescription, taken in conjunction with the accompanying drawings, inwhich like elements are given the same or analogous reference numbersand wherein:

FIG. 1 is a schematic of one general embodiment of the method and systemof the invention.

FIG. 1′ is a schematic of another general embodiment of the method andsystem of the invention.

FIG. 1″ is a schematic of another general embodiment of the method andsystem of the invention.

FIG. 1′″ is a schematic of another general embodiment of the method andsystem of the invention.

FIG. 2A is a schematic of a first phase of a first two-bed embodiment ofthe method and system of the invention.

FIG. 2B is a schematic of a second phase of the first two-bed embodimentof the method and system of the invention.

FIG. 2C is a schematic of a third phase of the first two-bed embodimentof the method and system of the invention.

FIG. 2D is a schematic of a fourth phase of the first two-bed embodimentof the method and system of the invention.

FIG. 2A′ is a schematic of a first phase of a second two-bed embodimentof the method and system of the invention.

FIG. 2B′ is a schematic of a second phase of the second two-bedembodiment of the method and system of the invention.

FIG. 2C′ is a schematic of a third phase of the second two-bedembodiment of the method and system of the invention.

FIG. 2D′ is a schematic of a third phase of the second two-bedembodiment of the method and system of the invention.

FIG. 2A″ is a schematic of a first phase of a third two-bed embodimentof the method and system of the invention.

FIG. 2B″ is a schematic of a second phase of the third two-bedembodiment of the method and system of the invention.

FIG. 2C″ is a schematic of a third phase of the third two-bed embodimentof the method and system of the invention.

FIG. 2D″ is a schematic of a fourth phase of the third two-bedembodiment of the method and system of the invention.

FIG. 2A′″ is a schematic of a first phase of a fourth two-bed embodimentof the method and system of the invention.

FIG. 2B′″ is a schematic of a second phase of the fourth two-bedembodiment of the method and system of the invention.

FIG. 2C′″ is a schematic of a third phase of the fourth two-bedembodiment of the method and system of the invention.

FIG. 2D′″ is a schematic of a fourth phase of the fourth two-bedembodiment of the method and system of the invention.

FIG. 3A is a schematic of a first phase of a first three-bed embodimentof the method and system of the invention.

FIG. 3B is a schematic of a second phase of the first three-bedembodiment of the method and system of the invention.

FIG. 3C is a schematic of a third phase of the first three-bedembodiment of the method and system of the invention.

FIG. 3A′ is a schematic of a first phase of a second three-bedembodiment of the method and system of the invention.

FIG. 3B′ is a schematic of a second phase of the second three-bedembodiment of the method and system of the invention.

FIG. 3C′ is a schematic of a third phase of the second three-bedembodiment of the method and system of the invention.

FIG. 3A″ is a schematic of a first phase of a third three-bed embodimentof the method and system of the invention.

FIG. 3B″ is a schematic of a second phase of the third three-bedembodiment of the method and system of the invention.

FIG. 3C″ is a schematic of a third phase of the third three-bedembodiment of the method and system of the invention.

FIG. 3A′″ is a schematic of a first phase of a fourth three-bedembodiment of the method and system of the invention.

FIG. 3B′″ is a schematic of a second phase of the fourth three-bedembodiment of the method and system of the invention.

FIG. 3C′″ is a schematic of a third phase of the fourth three-bedembodiment of the method and system of the invention.

FIG. 4A is a schematic of a first phase of a first four-bed embodimentof the method and system of the invention.

FIG. 4B is a schematic of a second phase of the first four-bedembodiment of the method and system of the invention.

FIG. 4C is a schematic of a third phase of the first four-bed embodimentof the method and system of the invention.

FIG. 4D is a schematic of a fourth phase of the four-bed embodiment ofthe method and system of the invention.

FIG. 4A′ is a schematic of a first phase of a second four-bed embodimentof the method and system of the invention.

FIG. 4B′ is a schematic of a second phase of the second four-bedembodiment of the method and system of the invention.

FIG. 4C′ is a schematic of a third phase of the second four-bedembodiment of the method and system of the invention.

FIG. 4D′ is a schematic of a fourth phase of the second four-bedembodiment of the method and system of the invention.

FIG. 4A″ is a schematic of a first phase of a third four-bed embodimentof the method and system of the invention.

FIG. 4B″ is a schematic of a second phase of the third four-bedembodiment of the method and system of the invention.

FIG. 4C″ is a schematic of a third phase of the third four-bedembodiment of the method and system of the invention.

FIG. 4D″ is a schematic of a third phase of the third four-bedembodiment of the method and system of the invention.

FIG. 4A′″ is a schematic of a first phase of a fourth four-bedembodiment of the method and system of the invention.

FIG. 4B′″ is a schematic of a second phase of the fourth four-bedembodiment of the method and system of the invention.

FIG. 4C′″ is a schematic of a third phase of the fourth four-bedembodiment of the method and system of the invention.

FIG. 4D′″ is a schematic of a third phase of the fourth four-bedembodiment of the method and system of the invention.

DESCRIPTION OF PREFERRED EMBODIMENTS

The invention is a hybrid PTSA/membrane method system for upgrading ofbiogas. It removes amounts of H₂S, water, VOCs, and CO₂ to yield aproduct gas meeting natural gas specifications. The H₂S content of theproduct gas is no more than 100 ppm (v/v) for on-site use in generatorsor no more than 4 ppm (v/v) for meeting typical pipeline specificationsfor sale. For pipeline quality natural gas, the H₂S level in the productgas may alternatively expressed as no more than 1 grain per 100 stdft³,typically no more than 0.3 grain per 100 stdft³. The product gas alsocontains no more than 0.4%, typically no more than 0.2% (v/v) of O₂, andno more than 2% (v/v) of CO₂.

The biogas may be obtained from a landfill or an anaerobic digester.

The composition of the raw landfill gas may vary but typically includes40-60% (v/v) methane, 40-60% (v/v) CO₂, 2-15% (v/v) N₂, 0.1-1% (v/v) O₂,0.001-0.3% NH₃ (v/v), 0.01-0.5 VOCs (excluding methane), and sometimesup to 1% (v/v) total sulfur compounds, up to 0.2% (v/v) H₂, up to 0.2%(v/v) CO, and varying levels of siloxanes. The H₂S content can vary aswidely as 50 ppm (v/v) to 15,000 ppm (v/v) but more typically is presentat levels of 100 ppm (v/v) or less.

The composition of the digester gas may vary depending upon the type ofwaste processed, such as animal waste, food processing waste, or sewage.Digester gas typically contains 55-70% (v/v) methane and 25-45% (v/v)CO₂. It also includes water at or near its dew point, 3-4 ppm (v/v) NH₃,and up to 50 ppm (v/v) siloxanes. The H₂S content of digester gas canreach as high as 10,000 ppm (v/v) H₂S, but more typically it is in therange of 40-3,000 ppm (v/v) and even more typically in the range of300-2,500 ppm (v/v).

Before feeding a stream of the biogas to a compressor, it may optionallybe passed through an inlet filter. The compressor compresses the biogasto a typical pressure of 50 to 500 psig, more typically 100-300 psig andoften 150-250 psig. The compressor is cooled with cooling oil which iscooled at a heat exchanger that is either integrated with the compressoror separate from the compressor.

The compressed biogas feed stream (i.e., the PTSA feed gas stream) isfed to a PTSA unit that includes two or more (typically 2-4) adsorbentbeds containing adsorbent. Each bed is selective for water, VOCs, andH₂S over CO₂ and for H₂S over methane. Each bed is optionally alsoselective for siloxanes over methane. The selectivity for H₂S over CO₂is not an arbitrary feature. While H₂S and CO₂ adsorb strongly on mostadsorbents used in the field of adsorbent-based gas separations, forgases containing relatively high levels of CO₂ in comparison to H₂S(such as biogas), the H₂S winds up being adsorbed in relatively loweramounts in comparison to CO₂. For this reason, it is important that theadsorbent beds be selective for H₂S over CO₂. Otherwise, much of theadsorption sites needed for adsorption of H₂S would tend to be blockedby adsorbed CO₂. The aforementioned selectivity properties may beaccomplished by using a single adsorbent meeting each of theseselectivities or by using multiple adsorbents in a layered bed. While itis desired to remove H₂O and VOCs at the same time as removing H₂S, theadsorbent used for H₂S removal may not be the most advantageous forremoval of H₂O or VOCs. Thus, multiple adsorbents can be used in thePTSA beds that are targeted to the composition of the PTSA feed gasstream being treated. Such adsorbents are normally installed in layersand such composite beds are commonly used and well know to one skilledin the art. The bed may be layered with an adsorbent particularlysuitable for sorbing water and VOCs at the inlet of the bed and adifferent adsorbent (downstream of the inlet) particularly suitable forsorbing H₂S. Further, as with other PTSA systems, the adsorber vesselsare insulated and either internal or external insulation can be appliedwith no change to the invention.

Suitable adsorbents include but are not limited to silica gel such asavailable from Grace or BASF (under the trade name Sorbead®), SulfaTrap™available from SulfaTrap, Inc., various molecular sieves including 4A,5A and 13X versions, natural zeolites, or alumina.

Each of the beds of the PTSA unit is operated in PTSA cycle phases ofadsorption, depressurization, thermal regeneration using a regenerationgas stream heated to a temperature above that of the PTSA feed gasstream, cool down using a cool down gas stream, and repressurizationwith the PTSA feed gas, PTSA product gas and/or retentate gas streamfrom a first or second gas separation membrane stage (discussed below).During the adsorption phase, the PTSA feed gas stream (typically at atemperature of about 0 to 40° C. and at a pressure of 50 to 500 psig,more typically 150-250 psig) is fed to a regenerated, cooled, andpressurized adsorbent bed that selectively adsorbs water, VOCs, and H₂Sfrom the PTSA feed gas stream to produce a “PTSA product gas” which isfurther upgraded by the gas separation membranes.

Following the adsorption phase, the adsorption bed is depressurized downto the pressure at which regeneration takes place, for example, at 14-20psia.

Once a suitable pressure has been reached, the adsorption bed isthermally regenerated by passing a relatively hot regeneration gasstream through the bed and desorbing the water, VOCs, and H₂S that wasadsorbed from the PTSA feed gas stream. A waste gas comprised of the gasof the thermal regeneration gas stream plus the desorbed water, VOCs,and H₂S is withdrawn from the PTSA unit.

While the regeneration temperature may be selected dependent upon theimpurities adsorbed upon the adsorbent from the PTSA feed gas stream andalso upon the selected adsorbent applied, typically the regenerationtemperature ranges from 250-600° F.

Following regeneration, the adsorbent bed is cooled down to a suitabletemperature to prepare it for the adsorption phase of the next PTSAcycle. Once the suitable temperate is reached, the adsorbent bed isrepressurized with PTSA feed gas in order to reach the pressuremaintained during the adsorption phase. Following the cool down andrepressurization, the PTSA cycle may be repeated.

A water, VOCs, and H₂S-depleted “PTSA product gas” stream is withdrawnfrom the PTSA unit and fed to a first of two gas separation membranestages each of which includes one or more gas separation membranes. Eachof the gas separation membranes of the two stages is selective forpermeating CO₂ and O₂ over methane. Thus, the first gas separationmembrane separates the PTSA product gas stream into a permeate gasstream that is enriched in CO₂ and O₂ over methane (in comparison to thePTSA product gas) and a retentate gas stream that is enriched in methaneover CO₂ and O₂ (in comparison to the PTSA product gas). While theselective layer of the membranes of the first gas separation membranestage may include any membrane known in the field of gas separationmembranes to be selective for CO₂ over methane, typically, the selectivelayer is made of a polyimide.

The first stage retentate gas stream is fed to the second gas separationmembrane stage. The second gas separation membrane stage separates thefirst stage retentate gas stream into a permeate gas stream that isenriched in CO₂ and O₂ over methane (in comparison to the first stageretentate gas stream) and a retentate gas stream that is enriched inmethane over CO₂ and O₂ (in comparison to the first stage retentate gasstream). The second stage retentate gas stream is withdrawn as theproduct gas meeting natural gas specifications as described above. Theselective layer of the membranes may be the same or different as that ofthe first gas separation membrane stage and may include any membraneknown in the field of gas separation membranes to be selective for CO₂over methane. Typically, the selective layer is made of a polyimide.

A stream of the waste gas withdrawn from the PTSA unit may be vented orsent to a treatment unit for destruction of the VOCs and H₂S. Suitabletreatment units include burners (which may be supplemented with naturalgas for flame stability) especially porous burners. Typically, however,the impurity-laden regeneration gas is treated in a thermal oxidizing(TOX) unit. The heat necessary for desorption of the impurities may beadded to the regeneration gas stream by an external heater, and may alsouse some or all of recovered heat from hot gas or hot oil from thecompressor or heat recovery from a thermal oxidizer or other source ofwaste heat.

While any gas may be used for thermal regeneration of the adsorbentbeds, in one aspect of the invention, all or some of the first stagepermeate gas stream is used as the thermal regeneration gas. Becausesome amounts of the methane contained in the PTSA product gas streamwill necessarily permeate across the membranes of the first gasseparation membrane stage, the first stage permeate gas stream will notonly include CO₂ but also methane. Typically, the first stage permeategas stream contains 5-13% (v/v) methane. Because the waste gas willinclude the methane from the first stage permeate gas stream, thermaloxidization or burning of the VOCs is enhanced by the presence of themethane. Additionally, in the event that the effluent from the hybridsystem of the invention is subject to regulatory control over the amountof methane emissions, those amounts of methane not recovered in theproduct natural gas stream will be burned or oxidized in the treatmentunit. Finally, through use of the first stage permeate gas stream as theregeneration gas stream, there is no need to provide another source ofgas that is suitably dry and impurity-free enough to allow satisfactoryamounts of water, VOCs, and H₂S to be desorbed from the adsorbent bedsduring thermal regeneration.

While any gas may be used to cool down regenerated adsorbent beds duringthe cool down phase of the PTSA cycle, in another aspect of theinvention, all or some of the second stage permeate gas stream is usedas the cool down gas stream. The second stage permeate gas streamwithdrawn from the adsorbent bed undergoing cool down (as a recyclestream) is fed to the suction inlet of the main compressor where it iscompressed and combined with the raw biogas feed stream to form the PTSAfeed gas stream. After the second stage permeate gas is used as the cooldown gas stream, it may be fed directly to the suction inlet of the maincompressor, or alternatively, it instead may be compressed in asecondary compressor. While this alternative routing of the second stagepermeate gas stream/recycle stream requires a second compressor, thesegases are largely free of impurities so they may be routed directly tothe first gas separation membrane stage after compression. This avoidsan increase in the flow rate of the PTSA feed gas stream that must betreated by the PTSA unit. As a result, the size and cost of the PTSAunit may be decreased in comparison to the general scheme where therecycle stream is compressed and combined with the raw biogas feedstream at the main compressor.

When the first stage permeate is used as the regeneration gas stream andthe second stage permeate is used as the cool down gas stream, variousPTSA cycles may be created depending upon the number of beds in the PTSAunit.

A three-bed PTSA unit maximizes the uses of the first and second stagepermeate gas streams as the regeneration and cool down gas streams. Fora three-bed PTSA unit, a typical cycle is described in Table I below.

TABLE I typical PTSA cycle for three beds Phase # 1 2 3 Bed # 1adsorption depressurization cool down then then repressurizationregeneration 2 cool down then adsorption depressurizationrepressurization then regeneration 3 depressurization cool down thenadsorption then regeneration repressurization

For feeds of biogas where excess regeneration gas is available, a moresimple two bed cycle can be applied. An example of when excessregeneration gas is available is when the feed gas contains relativelylow levels of impurities, such as low levels of H2S such that the amountof adsorbent to be heated is reduced as compared to a feed with higherlevels of impurities. A typical cycle for a two-bed PTSA unit isdescribed in Table II below.

TABLE II typical PTSA cycle for two beds Phase # 1 2 3 4 Bed # 1adsorption adsorption depressurization cool down then thenrepressurization regeneration 2 depressurization cool down thenadsorption adsorption then repressurization regeneration

While the three bed cycle is a basic approach the technology is notlimited by the cycle used. For example where upflow adsorption is used,the velocity of the feed gas can be limited by the fluidization velocityand using two vessels simultaneously for adsorption allows a moreoptimal process. A typical cycle for a four-bed PTSA unit is describedin Table III below.

TABLE III typical PTSA cycle for four beds Phase # 1 2 3 4 Bed # 1adsorption adsorption depressurization cool down then thenrepressurization regeneration 2 cool down then adsorption adsorptiondepressurization repressurization then regeneration 3 depressurizationcool down then adsorption adsorption then repressurization regeneration4 adsorption depressurization cool down then adsorption thenrepressurization regeneration

I will now proceed to describe some process configurations for carryingout the invention described above. One of ordinary skill in the art willrecognize that any of the aspects (including alternative embodiments orvariations) of the invention described above may be combined with any ofthe specific process configurations described below.

As best shown in FIGS. 1 and 1′, a stream of raw biogas 1 is fed to amain compressor 3. A PTSA feed gas stream 5 is received from thecompressor 3 and fed to one or more adsorbent beds the PTSA unit 7 thatare undergoing the repressurization phase and one or more adsorbent bedsthat are undergoing the adsorption phase. The adsorbent beds of the PTSAunit selectively adsorb, from the pressurized gas of the PTSA feed gasstream 5, H₂S, water, and VOCs (and optionally siloxanes) over methaneand H₂S over CO₂.

A PTSA product gas 9 deficient in H₂S, water, and VOCs (and optionallysiloxanes) and enriched in CH₄ and CO₂ in comparison to the PTSA feedgas stream 5 is withdrawn from one or more beds of the PTSA unit 7undergoing adsorption and fed to the first gas separation membrane stage11. The first gas separation membrane stage 11, including one or moregas separation membranes selective for CO₂ over methane separate thePTSA product gas stream 9 into a first stage permeate gas stream 13 anda first stage retentate gas stream 15.

The first stage retentate gas stream 15 is fed to the second gasseparation membrane stage 17. The second gas separation membrane stage,including one or more gas separation membranes selective for CO₂ overmethane separate the first stage retentate stream 15 into a second stagepermeate stream 19 and a second stage retentate stream 21. The secondstage retentate stream 21 is the product gas that is suitable foron-site use in generators or meets typical pipeline specifications forsale (as described above).

A waste stream 23 includes depressurization gas withdrawn from one ormore of the beds the PTSA unit 7 that are undergoing depressurization isfed to a treatment unit 25 where it is burned or thermally oxidized toyield a vent gas 27. After the one or more beds undergoingdepressurization are suitably depressurized, instead of bypassing thePTSA unit 7, the first stage permeate gas stream 13 is heated at aheater 29 and fed as a regeneration gas stream 31 to the one or moredepressurized adsorbent beds of the PTSA unit 7 that are undergoingregeneration. Thus, the waste stream 23 now includes the gas of theregeneration stream 31 plus impurities desorbed from the one or morebeds being regenerated and is fed to the treatment unit 25 for burningor thermal oxidization to yield the vent gas 27.

The second stage permeate gas stream 19 is fed to one or more beds ofthe PTSA unit 7 undergoing cool down and recycled as a recycle stream 35to a suction inlet of the main compressor 3 where it is combined andcompressed with the raw biogas stream 1 to yield the PTSA feed gasstream 5. Optionally, the recycle stream 35 may be cooled before beingfed to the suction inlet of the main compressor 3.

When the one or more beds undergoing cool down reach a suitabletemperature, the second stage permeate gas stream 19 is instead fed tothe suction inlet of the main compressor 3 where it combined andcompressed with the raw biogas stream 1 to produce the PTSA feed gasstream 5. Alternatively and as shown in FIG. 1′, instead of feeding therecycle stream 35 to the suction inlet of the main compressor 3, it iscompressed at a secondary compressor 37 and fed to the first gasseparation membrane stage 11. Optionally, stream 35 is cooled beforebeing fed to the suction inlet of the main or secondary compressor 3,37.

Regardless of whether the recycle stream 35 is fed to the maincompressor 3 or secondary compressor 37, simultaneous with this, thePTSA feed gas 5 is also fed to the one or more beds that have beencooled down in order to repressurize them in anticipation of undergoingadsorption in the next phase of the PTSA cycle. Optionally,repressurization is conducted with PTSA product gas and/or the first orsecond gas separation membrane stage retentate streams 15, 21.

In two particular embodiments and as best shown in FIGS. 1″ and 1′″,there are three membrane gas separation stages 11, 17, 18 each of whichincludes one or more gas separation membranes selective for CO₂ overmethane. The difference between the embodiments of FIGS. 1 and 1′ andthe embodiments of FIGS. 1″ and 1′″ is as follows. Instead of heatingthe first stage permeate gas stream 13 and using it as a regenerationgas stream for the one or more depressurized adsorbent beds of the PTSAunit 7 that are undergoing regeneration, additional amounts of methaneare recovered from the first stage permeate gas stream 13 at the thirdgas separation membrane stage 18. The first permeate gas stream 13 isfirst compressed at a tertiary compressor 14 to a pressure at or abovethat of the PTSA product gas stream 9 and subsequently fed to the thirdgas separation membrane stage 18 where it is separated into a thirdpermeate stream 20 and a third retentate stream 22. The third retentatestream 22 is fed, along with the PTSA product gas stream 9, to the firstgas separation membrane stage 11 where some of the methane recovered atthe third stage 18 may be recovered in the first retentate gas 15. Inthis embodiment, the third permeate stream 20 performs the samefunctions of the first permeate stream 13 in the embodiment of FIGS. 1and 1′. Thus, the regeneration stream 31 is fed to the one or moredepressurized adsorbent beds of the PTSA unit 7 that are undergoingregeneration so as to desorb impurities from the one or more beds beingregenerated. As with the embodiments of FIG. 1 and I′ the regenerationstream 31, now containing desorbed impurities, is fed to the treatmentunit 25 for burning or thermal oxidization to yield the vent gas 27.Finally, the embodiment of FIG. 1′″ differs from that of FIG. 1″ inthat, instead of feeding the recycle stream 35 to the suction inlet ofthe main compressor 3, in the embodiment of FIG. 1′″ it is compressed ata secondary compressor 37 and fed to the first gas separation membranestage 11. Optionally, stream 35 is cooled before being fed to thesuction inlet of the main or secondary compressor 3, 37.

In two other particulars embodiments and as best shown in FIGS. 2A-2Dand 2A′-2D′, the PTSA unit 7 includes two adsorbent beds 41, 42 thatundergo four phases in the PTSA cycle as shown in Table II above.

In a first phase of the embodiments of FIGS. 2A-2D and FIGS. 2A′-2D′ andas best shown in FIGS. 2A and 2A′, the raw biogas stream 1 is fed to andcompressed by the main compressor 3. The PTSA feed gas stream 5 iswithdrawn from the main compressor 3 and fed to a first adsorbent bed 41of the PTSA unit 7 (the outlines of which are not illustrated for sakeof clarity). The first adsorbent bed 41 undergoes adsorption in thefirst and second phases where it selectively adsorbs, from thepressurized gas of the PTSA feed gas stream 5, H₂S, water, and VOCs (andoptionally siloxanes) over methane and H₂S over CO₂.

The PTSA product gas 9 deficient in H₂S, water, and VOCs (and optionallysiloxanes) and enriched in CH₄ and CO₂ in comparison to the PTSA feedgas stream 5 is withdrawn from the first adsorbent bed 41 and fed to thefirst gas separation membrane stage 11. The first gas separationmembrane stage 11, including one or more gas separation membranesselective for CO₂ over methane separate the PTSA product gas stream 9into a first stage permeate gas stream 13 and a first stage retentategas stream 15. The first stage permeate gas stream 13 is fed to thetreatment unit 25 where it is burned or thermally oxidized to yield thevent gas 27.

The first stage retentate gas stream 15 is fed to the second gasseparation membrane stage 17. The second gas separation membrane stage,including one or more gas separation membranes selective for CO₂ overmethane separate the first stage retentate stream 15 into the secondstage permeate stream 19 and the second stage retentate stream 21. Thesecond stage retentate stream 21 is the product gas that is suitable foron-site use in generators or meets typical pipeline specifications forsale (as described above).

A waste stream 23 includes depressurization gas withdrawn from a secondadsorption bed 42 of the PTSA unit 7 that is undergoingdepressurization. The waste stream 23 is fed to the treatment unit 25where it is burned or thermally oxidized to yield the vent gas 27. Afterthe second bed 42 is suitably depressurized, instead of being directlyfed to the treatment unit 25 and bypassing the PTSA unit 7, the firststage permeate gas stream 13 is heated at the heater 29 and fed as aregeneration gas stream 31 to the second adsorbent bed 42 which nowundergoes regeneration. Thus, the waste stream 23 now includes the gasof the regeneration stream 31 plus impurities desorbed from the secondadsorbent bed and is fed to the treatment unit 25 for burning or thermaloxidization to yield the vent gas 27.

The second stage permeate gas stream 19 is recycled to the suction inletof the main compressor 3 where it is combined and compressed with theraw biogas stream 1 to yield the PTSA feed gas stream 5. Alternativelyand as illustrated in FIG. 2A′, the second stage permeate gas stream 19may be recycled to a suction inlet of a secondary compressor 37,compressed thereat, and subsequently fed to the first gas separationmembrane stage 11.

In a second phase of the embodiment of FIGS. 2A-2D and 2A′-2D′ and asbest shown in FIGS. 2B and 2B′, the raw biogas stream 1 is continued tobe fed to and compressed by the main compressor 3 and the PTSA feed gasstream 5 continues to be withdrawn from the main compressor 3 and fed tothe first adsorbent bed 41 of the PTSA unit 7 as explained above. Thefirst adsorbent bed 41 continues to undergoes adsorption as explainedabove.

Similarly, the PTSA product gas 9 is withdrawn from the first adsorbentbed 41 and fed to the first gas separation membrane stage 11 where it isseparated into a first stage permeate gas stream 13 and a first stageretentate gas stream 15.

The first stage retentate gas stream 15 is fed to the second gasseparation membrane stage 17. The second gas separation membrane stage,including one or more gas separation membranes selective for CO₂ overmethane separate the first stage retentate stream 15 into a second stagepermeate stream 19 and a second stage retentate stream 21. The secondstage retentate stream 21 is the product gas that is suitable foron-site use in generators or meets typical pipeline specifications forsale (as described above).

Instead of being fed to the second adsorbent bed 42 as a regenerationgas, the first stage permeate gas stream 13 is fed to the treatment unit25. The first stage retentate gas stream 15 is fed to the second gasseparation membrane stage 17 where it is separated into a second stagepermeate stream 19 and the second stage retentate stream 21.

The second stage permeate gas stream 19 is fed to the second adsorbentbed 42 (which is now undergoing cool down) and recycled as a recyclestream 35 (containing the gas of the second stage permeate gas plusimpurities desorbed from the second adsorbent bed 42) to a suction inletof the main compressor 3 where it is combined and compressed with theraw biogas stream 1 to yield the PTSA feed gas stream 5. Optionally, therecycle stream 35 may be cooled before being fed to the suction inlet ofthe main compressor 3.

When the second adsorbent bed 42 reaches a suitable temperature, thesecond stage permeate gas stream 19 bypasses the second adsorbent bed 42and is instead fed to the suction inlet of the main compressor 3 whereit combined and compressed with the raw biogas stream 1 to produce thePTSA feed gas stream 5. Simultaneous with this, the PTSA feed gas stream5 is also fed to the second adsorbent bed 42 in order to repressurize itin anticipation of undergoing adsorption in the third phase. Optionally,repressurization is conducted with PTSA product gas and/or the first orsecond gas separation membrane stage retentate gas streams 15, 21.

Alternatively and as shown in FIG. 2B′, instead of feeding the bypassingsecond stage permeate gas stream 19 to the suction inlet of the maincompressor 3, it is compressed at the suction inlet of the secondarycompressor 37, compressed thereat, and subsequently fed to the first gasseparation membrane stage 11. Optionally, the recycle stream 35 may becooled before being fed to the suction inlet of the secondary compressor37.

I note that, although streams 19 and 35 are illustrated as beingcontiguous along a common terminal branch in FIGS. 2B, 2B′, 2D, 2D′,3A-3C, 3A′-3C′, 4A-4D, and 4A′-4D′, the skilled artisan will recognizethat the flows of gas may be directed through a common section of pipingor different piping terminating at the main compressor 3.

In a third phase of the embodiment of FIGS. 2A-2D and 2A′-2D′ and asbest shown in FIGS. 2C and 2C′, the raw biogas stream 1 is fed to andcompressed by the main compressor 3. The PTSA feed gas stream 5 iswithdrawn from the main compressor 3 and is now fed to the secondadsorbent bed 42 instead of the first adsorbent bed 41. The secondadsorbent bed 42 undergoes adsorption in the third and fourth phaseswhere it selectively adsorbs, from the pressurized gas of the PTSA feedgas stream 5, H₂S, water, and VOCs (and optionally siloxanes) overmethane and H₂S over CO₂.

The PTSA product gas 9 deficient in H₂S, water, and VOCs (and optionallysiloxanes) and enriched in CH₄ and CO₂ in comparison to the PTSA feedgas stream 5 is withdrawn from the second adsorbent bed 42 and fed tothe first gas separation membrane stage 11. The first gas separationmembrane stage 11, including one or more gas separation membranesselective for CO₂ over methane separate the PTSA product gas stream 9into a first stage permeate gas stream 13 and a first stage retentategas stream 15. The first stage permeate gas stream 13 is initially fedto the treatment unit 25 where it is burned or thermally oxidized toyield the vent gas 27.

The first stage retentate gas stream 15 is fed to the second gasseparation membrane stage 17. The second gas separation membrane stage,including one or more gas separation membranes selective for CO₂ overmethane separate the first stage retentate stream 15 into the secondstage permeate stream 19 and the second stage retentate stream 21. Thesecond stage retentate stream 21 is the product gas as described above.

A waste stream 23 includes depressurization gas withdrawn from the firstadsorption bed 41 which is now undergoing depressurization. The wastestream 23 is fed to the treatment unit 25 where it is burned orthermally oxidized to yield the vent gas 27. After the first bed 41 issuitably depressurized, instead of being directly fed to the treatmentunit 25, the first stage permeate gas stream 13 is heated at the heater29 and fed as a regeneration gas stream 31 to the first adsorbent bed 41which is now undergoing regeneration. Thus, the waste stream 23 nowincludes the gas of the regeneration stream 31 plus impurities desorbedfrom the first adsorbent bed 41 and is fed to the treatment unit 25 forburning or thermal oxidization to yield the vent gas 27.

The second stage permeate gas stream 19 is recycled to the suction inletof the main compressor 3 where it is combined and compressed with theraw biogas stream 1 to yield the PTSA feed gas stream 5. Alternativelyand as shown in FIG. 2C′, the second stage permeate gas stream 19 is fedto the suction inlet of the secondary compressor 37, compressed thereat,and subsequently fed to the first gas separation membrane stage 11.Optionally, the recycle stream 35 may be cooled before being fed to thesuction inlet of the main compressor 3.

In a fourth phase of the embodiment of FIGS. 2A-2D and 2A′-2D′ and asbest shown in FIGS. 2D and 2D′, the raw biogas stream 1 is continued tobe fed to and compressed by the main compressor 3 and the PTSA feed gasstream 5 continues to be withdrawn from the main compressor 3 and fed tothe second adsorbent bed 42 as explained above. The first adsorbent bed42 continues to undergoes adsorption as explained above.

Similarly, the PTSA product gas 9 is withdrawn from the second adsorbentbed 42 and fed to the first gas separation membrane stage 11 where it isseparated into a first stage permeate gas stream 13 and a first stageretentate gas stream 15.

Instead of being fed to the first adsorbent bed 41 as a regenerationgas, the first stage permeate gas stream 13 is fed to the treatment unit25. The first stage retentate gas stream 15 is fed to the second gasseparation membrane stage 17 where it is separated into a second stagepermeate stream 19 and the second stage retentate stream 21.

The second stage permeate gas stream 19 is fed to the first adsorbentbed 41 (which is now undergoing cool down) and recycled as a recyclestream 35 to a suction inlet of the main compressor 3 where it iscombined and compressed with the raw biogas stream 1 to yield the PTSAfeed gas stream 5. Optionally, the recycle stream 35 may be cooledbefore being fed to the suction inlet of the main compressor 3.

When the first adsorbent bed 41 reaches a suitable temperature, thesecond stage permeate gas stream 19 bypasses the first adsorbent bed 41and is instead fed to the suction inlet of the main compressor 3 whereit combined and compressed with the raw biogas stream 1 to produce thePTSA feed gas stream 5. Simultaneous with this, the PTSA feed gas stream5 is also fed to the first adsorbent bed 41 in order to repressurize itin anticipation of undergoing adsorption in the third phase. Optionally,repressurization is conducted with PTSA product gas and/or the first orsecond gas separation membrane stage retentate gas streams 15, 21.

Alternatively and as shown in FIG. 2D′, instead of feeding the bypassingsecond stage permeate gas stream 19 to the suction inlet of the maincompressor 3, it is fed to the suction inlet of the secondary compressor37, compressed thereat, and fed to the first gas separation membranestage 11. Optionally, the recycle stream 35 may be cooled before beingfed to the suction inlet of the secondary compressor 37.

In two particular other embodiments illustrated in FIGS. 2A″-2D″ and2A′″-2D′″, there are three membrane gas separation stages 11, 17, 18each of which includes one or more gas separation membranes selectivefor CO₂ over methane. The difference between the embodiments of FIGS.2A-2D/2A′-2D′ and the embodiments of 2A″-2D″/2A′″-2D′″ is as follows.Instead of heating the first stage permeate gas stream 13 and using itas a regeneration gas stream for one of the adsorbent beds 41, 42 whichhave undergone depressurization, additional amounts of methane arerecovered from the first stage permeate gas stream 13 at the third gasseparation membrane stage 18. The first permeate gas stream 13 is firstcompressed at a tertiary compressor 14 to a pressure at or above that ofthe PTSA product gas stream 9 and subsequently fed to the third gasseparation membrane stage 18 where it is separated into a third permeatestream 20 and a third retentate stream 22. The third retentate stream 22is fed, along with the PTSA product gas stream 9, to the first gasseparation membrane stage 11 where some of the methane recovered at thethird stage 18 may be recovered in the first retentate gas 15. In thisembodiment, the third permeate stream 20 performs the same functions ofthe first permeate stream 13 in the embodiment of FIGS. 2A-2D and2A′-2D′. Thus, the regeneration stream 31 is fed to the adsorbent bed41, 42 (which has undergone regeneration) so as to desorb impuritiesfrom the one or more beds being regenerated. As with the embodiments ofFIGS. 2A-2D and 2A′-2D′, the regeneration stream 31, now containingdesorbed impurities, is fed to the treatment unit 25 for burning orthermal oxidization to yield the vent gas 27. Finally, the embodiment ofFIGS. 2A′″-2D′″ differs from that of FIGS. 2A″-2D″ in that, instead offeeding the recycle stream 35 to the suction inlet of the maincompressor 3, in the embodiment of FIGS. 2A′″-2D′″ it is compressed at asecondary compressor 37 and fed to the first gas separation membranestage 11. Optionally, stream 35 is cooled before being fed to thesuction inlet of the main or secondary compressor 3, 37.

In another embodiment and as best shown in FIGS. 3A-3C and 3A′-3C′, thePTSA unit 7 includes three adsorbent beds 41, 42, 43 that undergo threephases in the PTSA cycle as shown in Table I above.

In a first phase of the embodiment of FIGS. 3A-3C and 3A′-3C′ and asbest shown in FIGS. 3A and 3A′, the raw biogas stream 1 is fed to andcompressed by the main compressor 3. The PTSA feed gas stream 5 iswithdrawn from the main compressor 3 and fed to a first adsorbent bed 41of the PTSA unit 7 (the outlines of which are not illustrated for sakeof clarity). The first adsorbent bed 41 undergoes adsorption in thefirst and second phases where it selectively adsorbs, from thepressurized gas of the PTSA feed gas stream 5, H₂S, water, and VOCs (andoptionally siloxanes) over methane and H₂S over CO₂.

The PTSA product gas 9 deficient in H₂S, water, and VOCs (and optionallysiloxanes) and enriched in CH₄ and CO₂ in comparison to the PTSA feedgas stream 5 is withdrawn from the first adsorbent bed 41 and fed to afeed gas inlet of the first gas separation membrane stage 11. The firstgas separation membrane stage 11, including one or more gas separationmembranes selective for CO₂ over methane separate the PTSA product gasstream 9 into a first stage permeate gas stream 13 and a first stageretentate gas stream 15. The first stage permeate gas stream 13,withdrawn from a permeate gas outlet of the first gas separationmembrane stage, is initially fed to the treatment unit 25 where it isburned or thermally oxidized to yield the vent gas 27.

The first stage retentate gas stream 15, withdrawn from a retentate gasoutlet of the first gas separation membrane stage, is fed to the secondgas separation membrane stage 17. The second gas separation membranestage, including one or more gas separation membranes selective for CO₂over methane separate the first stage retentate stream 15 into thesecond stage permeate stream 19 and the second stage retentate stream21. The second stage retentate stream 21 is the product gas that issuitable for on-site use in generators or meets typical pipelinespecifications for sale (as described above).

A waste stream 23 includes depressurization gas withdrawn from the thirdadsorption bed 43 of the PTSA unit 7 that is undergoingdepressurization. The waste stream 23 is fed to the treatment unit 25where it is burned or thermally oxidized to yield the vent gas 27. Afterthe third bed 43 is suitably depressurized, instead of being directlyfed to the treatment unit 25 and bypassing the PTSA unit 7, the firststage permeate gas stream 13 is heated at the heater 29 and fed as aregeneration gas stream 31 to the third adsorbent bed 42 which nowundergoes regeneration. Thus, the waste stream 23 now includes the gasof the regeneration stream 31 plus impurities desorbed from the thirdadsorbent bed and is fed to the treatment unit 25 for burning or thermaloxidization to yield the vent gas 27.

The second stage permeate gas stream 19 is fed to the second adsorbentbed 42 which is undergoing cool down and recycled as a recycle stream 35(containing the gas of the second stage permeate gas plus impuritiesdesorbed from the second adsorbent bed 42) to a suction inlet of themain compressor 3 where it is combined and compressed with the rawbiogas stream 1 to yield the PTSA feed gas stream 5. Optionally, therecycle stream 35 may be cooled before being fed to the suction inlet ofthe main compressor 3.

When the second adsorbent bed reaches a suitable temperature, the secondstage permeate gas stream 19 is instead fed to the suction inlet of themain compressor 3 where it combined and compressed with the raw biogasstream 1 to produce the PTSA feed gas stream 5. Simultaneous with this,the PTSA feed gas 5 is also fed to the second adsorbent bed 42 in orderto repressurize it in anticipation of undergoing adsorption in the nextphase of the PTSA cycle. Optionally, repressurization is conducted withPTSA product gas and/or the first or second gas separation membranestage retentate gas streams 15, 21.

Alternatively and as shown in FIG. 3A′, instead of feeding the recyclestream 35 or the second stage permeate gas stream 19 to the suctioninlet of the main compressor 3, each may be fed to the suction inlet ofthe secondary compressor 37, compressed thereat, and subsequently fed tothe first gas separation membrane stage 11. Optionally, the recyclestream 35 may be cooled before being fed to the suction inlet of thesecondary compressor 37.

In a second phase of the embodiment of FIGS. 3A-3C and 3A′-3C′ and asbest shown in FIGS. 3B and 3B′, the raw biogas stream 1 is continued tobe fed to and compressed by the main compressor 3, but the PTSA feed gasstream 5 withdrawn from the main compressor 3 is now fed to the secondadsorbent bed 42 as explained above.

The PTSA product gas 9 is withdrawn from the second adsorbent bed 42 andfed to the first gas separation membrane stage 11 where it is separatedinto a first stage permeate gas stream 13 and a first stage retentategas stream 15. The first stage permeate gas stream 13 is initially fedto the treatment unit 25 where it is burned or thermally oxidized toyield the vent gas 27.

The first stage retentate gas stream 15 is fed to the second gasseparation membrane stage 17. The second gas separation membrane stage,including one or more gas separation membranes selective for CO₂ overmethane separate the first stage retentate stream 15 into the secondstage permeate stream 19 and the second stage retentate stream 21. Thesecond stage retentate stream 21 is the product gas that is suitable foron-site use in generators or meets typical pipeline specifications forsale (as described above).

A waste stream 23 includes depressurization gas withdrawn from the firstadsorption bed 41 of the PTSA unit 7 that is undergoingdepressurization. The waste stream 23 is fed to the treatment unit 25where it is burned or thermally oxidized to yield the vent gas 27. Afterthe first bed 41 is suitably depressurized, instead of being directlyfed to the treatment unit 25 and bypassing the PTSA unit 7, the firststage permeate gas stream 13 is heated at the heater 29 and fed as aregeneration gas stream 31 to the first adsorbent bed 41 which nowundergoes regeneration. Thus, the waste stream 23 now includes the gasof the regeneration stream 31 plus impurities desorbed from the firstadsorbent bed 41 and is fed to the treatment unit 25 for burning orthermal oxidization to yield the vent gas 27.

The second stage permeate gas stream 19 is fed to the third adsorbentbed 43 (which is now undergoing cool down) and recycled as a recyclestream 35 (containing the gas of the second stage permeate gas plusimpurities desorbed from the third adsorbent bed 43) to a suction inletof the main compressor 3 where it is combined and compressed with theraw biogas stream 1 to yield the PTSA feed gas stream 5. Optionally, therecycle stream 35 may be cooled before being fed to the suction inlet ofthe main compressor 3.

When the third adsorbent bed 43 reaches a suitable temperature, thesecond stage permeate gas stream 19 bypasses the third adsorbent bed 43and is instead fed to the suction inlet of the main compressor 3 whereit combined and compressed with the raw biogas stream 1 to produce thePTSA feed gas stream 5. Simultaneous with this, the PTSA feed gas stream5 is also fed to the third adsorbent bed 43 in order to repressurize itin anticipation of undergoing adsorption in the third phase. Optionally,repressurization is conducted with PTSA product gas and/or the first orsecond gas separation membrane stage retentate gas streams 15, 21.

Alternatively and as shown in FIG. 3B′, instead of feeding the secondstage permeate gas stream 19 or the recycle stream 35 to the suctioninlet of the main compressor 3, both may be fed to the suction inlet ofthe secondary compressor 37, compressed thereat, and subsequently fed tothe first gas separation membrane stage 11. Optionally, the recyclestream 35 may be cooled before being fed to the suction inlet of thesecondary compressor 37.

In a third phase of the embodiment of FIGS. 3A-C and 3A′-3C′ and as bestshown in FIG. 3C and FIG. 3C′, the raw biogas stream 1 is fed to andcompressed by the main compressor 3. The PTSA feed gas stream 5 iswithdrawn from the main compressor 3 and is now fed to the thirdadsorbent bed 43 instead of the second adsorbent bed 42. The thirdadsorbent bed 43 undergoes adsorption in the third and fourth phaseswhere it selectively adsorbs, from the pressurized gas of the PTSA feedgas stream 5, H₂S, water, and VOCs (and optionally siloxanes) overmethane and H₂S over CO₂.

The PTSA product gas 9 deficient in H₂S, water, and VOCs (and optionallysiloxanes) and enriched in CH₄ and CO₂ in comparison to the PTSA feedgas stream 5 is withdrawn from the third adsorbent bed 43 and fed to thefirst gas separation membrane stage 11. The first gas separationmembrane stage 11, including one or more gas separation membranesselective for CO₂ over methane separate the PTSA product gas stream 9into a first stage permeate gas stream 13 and a first stage retentategas stream 15. The first stage permeate gas stream 13 is initially fedto the treatment unit 25 where it is burned or thermally oxidized toyield the vent gas 27.

The first stage retentate gas stream 15 is fed to the second gasseparation membrane stage 17. The second gas separation membrane stage,including one or more gas separation membranes selective for CO₂ overmethane separate the first stage retentate stream 15 into the secondstage permeate stream 19 and the second stage retentate stream 21. Thesecond stage retentate stream 21 is the product gas as described above.

A waste stream 23 includes depressurization gas withdrawn from thesecond adsorption bed 42 which is now undergoing depressurization. Thewaste stream 23 is fed to the treatment unit 25 where it is burned orthermally oxidized to yield the vent gas 27. After the second bed 42 issuitably depressurized, instead of being directly fed to the treatmentunit 25, the first stage permeate gas stream 13 is heated at the heater29 and fed as a regeneration gas stream 31 to the second adsorbent bed42 which is now undergoing regeneration. Thus, the waste stream 23 nowincludes the gas of the regeneration stream 31 plus impurities desorbedfrom the second adsorbent bed 42 and is fed to the treatment unit 25 forburning or thermal oxidization to yield the vent gas 27.

The second stage permeate gas stream 19 is fed to the first adsorbentbed 41 (which is now undergoing cool down) and recycled as a recyclestream 35 to a suction inlet of the main compressor 3 where it iscombined and compressed with the raw biogas stream 1 to yield the PTSAfeed gas stream 5. Optionally, the recycle stream 35 may be cooledbefore being fed to the suction inlet of the main compressor 3.

When the first adsorbent bed 41 reaches a suitable temperature, thesecond stage permeate gas stream 19 bypasses the first adsorbent bed 41and is instead fed to the suction inlet of the main compressor 3 whereit combined and compressed with the raw biogas stream 1 to produce thePTSA feed gas stream 5. Simultaneous with this, the PTSA feed gas stream5 is also fed to the first adsorbent bed 41 in order to repressurize itin anticipation of undergoing adsorption in the third phase. Optionally,repressurization is conducted with PTSA product gas and/or the first orsecond gas separation membrane stage retentate gas streams 15, 21.

Alternatively and as shown in FIG. 3C′, instead of feeding the secondstage permeate gas stream 19 or the recycle stream 35 to the suctioninlet of the main compressor 3, both may be fed to the suction inlet ofthe secondary compressor 37, compressed thereat, and subsequently fed tothe first gas separation membrane stage 11.

In two particular other embodiments illustrated in FIGS. 3A″-3C″ and3A′″-3C′″, there are three membrane gas separation stages 11, 17, 18each of which includes one or more gas separation membranes selectivefor CO₂ over methane.

The difference between the embodiments of FIGS. 3A-3C/3A′-3C′ and theembodiments of 3A″-3C″/3A′″-3C′″ is as follows. Instead of heating thefirst stage permeate gas stream 13 and using it as a regeneration gasstream for one of the adsorbent beds 41, 42, 43 which have undergonedepressurization, additional amounts of methane are recovered from thefirst stage permeate gas stream 13 at the third gas separation membranestage 18. The first permeate gas stream 13 is first compressed at atertiary compressor 14 to a pressure at or above that of the PTSAproduct gas stream 9 and subsequently fed to the third gas separationmembrane stage 18 where it is separated into a third permeate stream 20and a third retentate stream 22. The third retentate stream 22 is fed,along with the PTSA product gas stream 9, to the first gas separationmembrane stage 11 where some of the methane recovered at the third stage18 may be recovered in the first retentate gas 15. In this embodiment,the third permeate stream 20 performs the same functions of the firstpermeate stream 13 in the embodiment of FIGS. 3A-3C and 3A′-3C′. Thus,the regeneration stream 31 is fed to the adsorbent bed 41, 42, 43 (whichhas undergone regeneration) so as to desorb impurities from the one ormore beds being regenerated. As with the embodiments of FIGS. 3A-3C and3A′-3C′, the regeneration stream 31, now containing desorbed impurities,is fed to the treatment unit 25 for burning or thermal oxidization toyield the vent gas 27. Finally, the embodiment of FIGS. 3A′″-3C′″differs from that of FIGS. 3A″-3C″ in that, instead of feeding therecycle stream 35 to the suction inlet of the main compressor 3, in theembodiment of FIGS. 3A′″-3C′″ it is compressed at a secondary compressor37 and fed to the first gas separation membrane stage 11. Optionally,stream 35 is cooled before being fed to the suction inlet of the main orsecondary compressor 3, 37.

In another embodiment and as best shown in FIGS. 4A-4D and 4A′-4D′, thePTSA unit 7 includes four adsorbent beds 41, 42, 43, 44 that undergothree phases in the PTSA cycle as shown in Table III above.

In a first phase of the embodiment of FIGS. 4A-4D and 4A′-4D′ and asbest shown in FIGS. 4A and 4A′, the raw biogas stream 1 is fed to andcompressed by the main compressor 3. The PTSA feed gas stream 5 iswithdrawn from the main compressor 3 and fed to the first and fourthadsorbent beds 41, 44 of the PTSA unit 7 (the outlines of which are notillustrated for sake of clarity) which selectively adsorb, from thepressurized gas of the PTSA feed gas stream 5, H₂S, water, and VOCs (andoptionally siloxanes) over methane and H₂S over CO₂.

The PTSA product gas 9 deficient in H₂S, water, and VOCs (and optionallysiloxanes) and enriched in CH₄ and CO₂ in comparison to the PTSA feedgas stream 5 is withdrawn from the first and fourth adsorbent beds 41,44 and fed to the first gas separation membrane stage 11. The first gasseparation membrane stage 11, including one or more gas separationmembranes selective for CO₂ over methane separate the PTSA product gasstream 9 into a first stage permeate gas stream 13 and a first stageretentate gas stream 15. The first stage permeate gas stream 13 isinitially fed to the treatment unit 25 where it is burned or thermallyoxidized to yield the vent gas 27.

The first stage retentate gas stream 15 is fed to the second gasseparation membrane stage 17. The second gas separation membrane stage,including one or more gas separation membranes selective for CO₂ overmethane separate the first stage retentate stream 15 into the secondstage permeate stream 19 and the second stage retentate stream 21. Thesecond stage retentate stream 21 is the product gas that is suitable foron-site use in generators or meets typical pipeline specifications forsale (as described above).

A waste stream 23 includes depressurization gas withdrawn from the thirdadsorption bed 43 of the PTSA unit 7 that is undergoingdepressurization. The waste stream 23 is fed to the treatment unit 25where it is burned or thermally oxidized to yield the vent gas 27. Afterthe third bed 43 is suitably depressurized, instead of being directlyfed to the treatment unit 25 and bypassing the PTSA unit 7, the firststage permeate gas stream 13 is heated at the heater 29 and fed as aregeneration gas stream 31 to the third adsorbent bed 43 which nowundergoes regeneration. Thus, the waste stream 23 now includes the gasof the regeneration stream 31 plus impurities desorbed from the thirdadsorbent bed and is fed to the treatment unit 25 for burning or thermaloxidization to yield the vent gas 27.

The second stage permeate gas stream 19 is fed to the second adsorbentbed 42 which is undergoing cool down and recycled as a recycle stream 35to a suction inlet of the main compressor 3 where it is combined andcompressed with the raw biogas stream 1 to yield the PTSA feed gasstream 5. Optionally, the recycle stream 35 may be cooled before beingfed to the suction inlet of the main compressor 3.

When the second adsorbent bed reaches a suitable temperature, the secondstage permeate gas stream 19 is instead fed to the suction inlet of themain compressor 3 where it combined and compressed with the raw biogasstream 1 to produce the PTSA feed gas stream 5. Simultaneous with this,the PTSA feed gas 5 is also fed to the second adsorbent bed 42 in orderto repressurize it in anticipation of undergoing adsorption in the nextphase of the PTSA cycle. Optionally, repressurization is conducted withPTSA product gas and/or the first or second gas separation membranestage retentate gas streams 15, 21.

Alternatively and as shown in FIG. 4A′, instead of feeding the secondstage permeate gas stream 19 or the recycle stream 35 to the suctioninlet of the main compressor 3, both may be fed to the suction inlet ofthe secondary compressor 37, compressed thereat, and subsequently fed tothe first gas separation membrane stage 11. Optionally, the recyclestream 35 may be cooled before being fed to the suction inlet of thesecondary compressor 37.

In a second phase of the embodiment of FIGS. 4A-4D and 4A′-4D′ and asbest shown in FIGS. 4B and 4B′, the raw biogas stream 1 is continued tobe fed to and compressed by the main compressor 3, and the PTSA feed gasstream 5 withdrawn from the main compressor 3 is still fed to the firstadsorbent bed 41. In this second phase, however, the PTSA feed gasstream 5 withdrawn from the main compressor 3 is no longer fed to thefourth adsorbent bed 44 but is instead fed to the second adsorbent bed42. Thus, the first and second adsorbent beds 41, 42 undergo adsorptionwhere they selectively adsorb, from the pressurized gas of the PTSA feedgas stream 5, H₂S, water, and VOCs (and optionally siloxanes) overmethane and H₂S over CO₂.

The PTSA product gas 9 is withdrawn from the first and second adsorbentbeds 41, 42 and fed to the first gas separation membrane stage 11 whereit is separated into a first stage permeate gas stream 13 and a firststage retentate gas stream 15. The first stage permeate gas stream 13 isinitially fed to the treatment unit 25 where it is burned or thermallyoxidized to yield the vent gas 27.

The first stage retentate gas stream 15 is fed to the second gasseparation membrane stage 17. The second gas separation membrane stage,including one or more gas separation membranes selective for CO₂ overmethane separate the first stage retentate stream 15 into the secondstage permeate stream 19 and the second stage retentate stream 21. Thesecond stage retentate stream 21 is the product gas that is suitable foron-site use in generators or meets typical pipeline specifications forsale (as described above).

A waste stream 23 includes depressurization gas withdrawn from thefourth adsorption bed 44 of the PTSA unit 7 that is undergoingdepressurization. The waste stream 23 is fed to the treatment unit 25where it is burned or thermally oxidized to yield the vent gas 27. Afterthe first bed 44 is suitably depressurized, instead of being directlyfed to the treatment unit 25 and bypassing the PTSA unit 7, the firststage permeate gas stream 13 is heated at the heater 29 and fed as aregeneration gas stream 31 to the fourth adsorbent bed 44 which nowundergoes regeneration. Thus, the waste stream 23 now includes the gasof the regeneration stream 31 plus impurities desorbed from the fourthadsorbent bed 44 and is fed to the treatment unit 25 for burning orthermal oxidization to yield the vent gas 27.

The second stage permeate gas stream 19 is fed to the third adsorbentbed 43 (which is now undergoing cool down) and recycled as a recyclestream 35 to a suction inlet of the main compressor 3 where it iscombined and compressed with the raw biogas stream 1 to yield the PTSAfeed gas stream 5. Optionally, the recycle stream 35 may be cooledbefore being fed to the suction inlet of the main compressor 3.

When the third adsorbent bed 43 reaches a suitable temperature, thesecond stage permeate gas stream 19 bypasses the third adsorbent bed 43and is instead fed to the suction inlet of the main compressor 3 whereit combined and compressed with the raw biogas stream 1 to produce thePTSA feed gas stream 5. Simultaneous with this, the PTSA feed gas stream5 is also fed to the third adsorbent bed 43 in order to repressurize itin anticipation of undergoing adsorption in the third phase. Optionally,repressurization is conducted with PTSA product gas and/or the first orsecond gas separation membrane stage retentate gas streams 15, 21.

Alternatively and as shown in FIG. 4B′, instead of feeding the secondstage permeate gas stream 19 or the recycle stream 35 to the suctioninlet of the main compressor 3, both may be fed to the suction inlet ofthe secondary compressor 37, compressed thereat, and subsequently fed tothe first gas separation membrane stage 11. Optionally, the recyclestream 35 may be cooled before being fed to the suction inlet of thesecondary compressor 37.

In a third phase of the embodiment of FIGS. 4A-D and 4A′-3D′ and as bestshown in FIG. 4C and FIG. 4C′, the raw biogas stream 1 is fed to andcompressed by the main compressor 3. The PTSA feed gas stream 5continues to be withdrawn from the main compressor 3 and fed to thesecond adsorbent bed 42. In this third phase, however, instead of alsofeeding the PTSA feed gas stream 5 to the first adsorbent bed 41, it isnow fed to the third adsorbent bed 43. Thus, the second and thirdadsorbent beds 42, 43 undergo adsorption where they selectively adsorbs,from the pressurized gas of the PTSA feed gas stream 5, H₂S, water, andVOCs (and optionally siloxanes) over methane and H₂S over CO₂.

The PTSA product gas 9 deficient in H₂S, water, and VOCs (and optionallysiloxanes) and enriched in CH₄ and CO₂ in comparison to the PTSA feedgas stream 5 is withdrawn from the second and third adsorbent beds 42,43 and fed to the first gas separation membrane stage 11. The first gasseparation membrane stage 11, including one or more gas separationmembranes selective for CO₂ over methane separate the PTSA product gasstream 9 into a first stage permeate gas stream 13 and a first stageretentate gas stream 15. The first stage permeate gas stream 13 isinitially fed to the treatment unit 25 where it is burned or thermallyoxidized to yield the vent gas 27.

The first stage retentate gas stream 15 is fed to the second gasseparation membrane stage 17. The second gas separation membrane stage,including one or more gas separation membranes selective for CO₂ overmethane separate the first stage retentate stream 15 into the secondstage permeate stream 19 and the second stage retentate stream 21. Thesecond stage retentate stream 21 is the product gas as described above.

A waste stream 23 includes depressurization gas withdrawn from the firstadsorption bed 41 which is now undergoing depressurization. The wastestream 23 is fed to the treatment unit 25 where it is burned orthermally oxidized to yield the vent gas 27. After the first bed 41 issuitably depressurized, instead of being directly fed to the treatmentunit 25, the first stage permeate gas stream 13 is heated at the heater29 and fed as a regeneration gas stream 31 to the first adsorbent bed 41which is now undergoing regeneration. Thus, the waste stream 23 nowincludes the gas of the regeneration stream 31 plus impurities desorbedfrom the first adsorbent bed 41 and is fed to the treatment unit 25 forburning or thermal oxidization to yield the vent gas 27.

The second stage permeate gas stream 19 is fed to the fourth adsorbentbed 44 (which is now undergoing cool down) and recycled as a recyclestream 35 to a suction inlet of the main compressor 3 where it iscombined and compressed with the raw biogas stream 1 to yield the PTSAfeed gas stream 5. Optionally, the recycle stream 35 may be cooledbefore being fed to the suction inlet of the main compressor 3.

When the fourth adsorbent bed 44 reaches a suitable temperature, thesecond stage permeate gas stream 19 is instead fed to the suction inletof the main compressor 3 where it combined and compressed with the rawbiogas stream 1 to produce the PTSA feed gas stream 5. Simultaneous withthis, the PTSA feed gas stream 5 is also fed to the fourth adsorbent bed44 in order to repressurize it in anticipation of undergoing adsorptionin the fourth phase. Optionally, repressurization is conducted with PTSAproduct gas and/or the first or second gas separation membrane stageretentate gas streams 15, 21.

Alternatively and as shown in FIG. 4C′, instead of feeding the secondstage permeate gas stream 19 or the recycle stream 35 to the suctioninlet of the main compressor 3, both may be fed to the suction inlet ofthe secondary compressor 37, compressed thereat, and subsequently fed tothe first gas separation membrane stage 11. Optionally, the recyclestream 35 may be cooled before being fed to the suction inlet of thesecondary compressor 37.

In a fourth phase of the embodiment of FIGS. 4A-D and 4A′-4D′ and asbest shown in FIG. 4D and FIG. 4D′, the raw biogas stream 1 is fed toand compressed by the main compressor 3. The PTSA feed gas stream 5continues to be withdrawn from the main compressor 3 and fed to thethird adsorbent bed 43. In this fourth phase, however, instead of alsofeeding the PTSA feed gas stream 5 to the second adsorbent bed 42, it isnow fed to the fourth adsorbent bed 44. Thus, the third and fourthadsorbent beds 43, 44 undergo adsorption where they selectively adsorb,from the pressurized gas of the PTSA feed gas stream 5, H₂S, water, andVOCs (and optionally siloxanes) over methane and H₂S over CO₂.

The PTSA product gas 9 deficient in H₂S, water, and VOCs (and optionallysiloxanes) and enriched in CH₄ and CO₂ in comparison to the PTSA feedgas stream 5 is withdrawn from the third and fourth adsorbent beds 43,44 and fed to the first gas separation membrane stage 11. The first gasseparation membrane stage 11, including one or more gas separationmembranes selective for CO₂ over methane separate the PTSA product gasstream 9 into a first stage permeate gas stream 13 and a first stageretentate gas stream 15. The first stage permeate gas stream 13 isinitially fed to the treatment unit 25 where it is burned or thermallyoxidized to yield the vent gas 27.

The first stage retentate gas stream 15 is fed to the second gasseparation membrane stage 17. The second gas separation membrane stage,including one or more gas separation membranes selective for CO₂ overmethane separate the first stage retentate stream 15 into the secondstage permeate stream 19 and the second stage retentate stream 21. Thesecond stage retentate stream 21 is the product gas as described above.

A waste stream 23 includes depressurization gas withdrawn from thesecond adsorption bed 42 which is now undergoing depressurization. Thewaste stream 23 is fed to the treatment unit 25 where it is burned orthermally oxidized to yield the vent gas 27. After the second bed 42 issuitably depressurized, instead of being directly fed to the treatmentunit 25, the first stage permeate gas stream 13 is heated at the heater29 and fed as a regeneration gas stream 31 to the second adsorbent bed42 which is now undergoing regeneration. Thus, the waste stream 23 nowincludes the gas of the regeneration stream 31 plus impurities desorbedfrom the second adsorbent bed 42 and is fed to the treatment unit 25 forburning or thermal oxidization to yield the vent gas 27.

The second stage permeate gas stream 19 is fed to the first adsorbentbed 41 (which is now undergoing cool down) and recycled as a recyclestream 35 to a suction inlet of the main compressor 3 where it iscombined and compressed with the raw biogas stream 1 to yield the PTSAfeed gas stream 5. Optionally, the recycle stream 35 may be cooledbefore being fed to the suction inlet of the main compressor 3.

When the first adsorbent bed 41 reaches a suitable temperature, thesecond stage permeate gas stream 19 is instead fed to the suction inletof the main compressor 3 where it combined and compressed with the rawbiogas stream 1 to produce the PTSA feed gas stream 5. Simultaneous withthis, the PTSA feed gas stream 5 is also fed to the first adsorbent bed41 in order to repressurize it in anticipation of undergoing adsorptionin the third phase. Optionally, repressurization is conducted with PTSAproduct gas and/or the first or second gas separation membrane stageretentate gas streams 15, 21.

Alternatively and as shown in FIG. 4D′, instead of feeding the secondstage permeate gas stream 19 or the recycle stream 35 to the suctioninlet of the main compressor 3, both may be fed to the suction inlet ofthe secondary compressor 37, compressed thereat, and subsequently fed tothe first gas separation membrane stage 11. Optionally the recyclestream 35 may be cooled before being fed to the suction inlet of thesecondary compressor 37.

In two particular other embodiments illustrated in FIGS. 4A″-4D″ and4A′″-4D′″, there are three membrane gas separation stages 11, 17, 18each of which includes one or more gas separation membranes selectivefor CO₂ over methane. The difference between the embodiments of FIGS.4A-4D/4A′-4D′ and the embodiments of 4A″-4D″/4A′″-4D′″ is as follows.Instead of heating the first stage permeate gas stream 13 and using itas a regeneration gas stream for one of the adsorbent beds 41, 42, 43which have undergone depressurization, additional amounts of methane arerecovered from the first stage permeate gas stream 13 at the third gasseparation membrane stage 18. The first permeate gas stream 13 is firstcompressed at a tertiary compressor 14 to a pressure at or above that ofthe PTSA product gas stream 9 and subsequently fed to the third gasseparation membrane stage 18 where it is separated into a third permeatestream 20 and a third retentate stream 22. The third retentate stream 22is fed, along with the PTSA product gas stream 9, to the first gasseparation membrane stage 11 where some of the methane recovered at thethird stage 18 may be recovered in the first retentate gas 15. In thisembodiment, the third permeate stream 20 performs the same functions ofthe first permeate stream 13 in the embodiment of FIGS. 4A-4D and4A′-4D′. Thus, the regeneration stream 31 is fed to the adsorbent bed41, 42, 43 (which has undergone regeneration) so as to desorb impuritiesfrom the one or more beds being regenerated. As with the embodiments ofFIGS. 4A-4D and 4A′-4D′, the regeneration stream 31, now containingdesorbed impurities, is fed to the treatment unit 25 for burning orthermal oxidization to yield the vent gas 27. Finally, the embodiment ofFIGS. 4A′″-4D′″ differs from that of FIGS. 4A″-4D″ in that, instead offeeding the recycle stream 35 to the suction inlet of the maincompressor 3, in the embodiment of FIGS. 4A′″-4D′″ it is compressed at asecondary compressor 37 and fed to the first gas separation membranestage 11. Optionally, stream 35 is cooled before being fed to thesuction inlet of the main or secondary compressor 3, 37.

I note that, for the sake of clarity, heater 29 is not illustrated inany of FIGS. 2A-2D, 2A′-2D′, 2A-2D″, 2A′″-2D′″, 3A-3C, 3A′-3C′, 3A″-3C″,3A′″-3C′″, 4A-4D, 4A′-D′, 4A″-4D″, or 4A′″-D′″, but it should beunderstood as present in each of those schemes for the purpose ofheating the first stage permeate stream 13 as discussed above.

Finally, I note that aspects of the invention are not limited to the useof first and/or second gas separation membrane stage retentate gasstreams 15, 21 for use as the regeneration and cool down gases. Indeed,any permutation of three or more gas separation membrane stages may beused in which any one or more of the permeate streams (the entirety of astream or only a portion of a stream) may be used as the regenerationgas and/or cool down gas.

While the invention has been described in conjunction with specificembodiments thereof, it is evident that many alternatives,modifications, and variations will be apparent to those skilled in theart in light of the foregoing description. Accordingly, it is intendedto embrace all such alternatives, modifications, and variations as fallwithin the spirit and broad scope of the appended claims. The presentinvention may suitably comprise, consist or consist essentially of theelements disclosed and may be practiced in the absence of an element notdisclosed. Furthermore, if there is language referring to order, such asfirst and second, it should be understood in an exemplary sense and notin a limiting sense. For example, it can be recognized by those skilledin the art that certain steps can be combined into a single step.

The singular forms “a”, “an” and “the” include plural referents, unlessthe context clearly dictates otherwise.

“Comprising” in a claim is an open transitional term which means thesubsequently identified claim elements are a nonexclusive listing i.e.anything else may be additionally included and remain within the scopeof “comprising.” “Comprising” is defined herein as necessarilyencompassing the more limited transitional terms “consisting essentiallyof” and “consisting of”; “comprising” may therefore be replaced by“consisting essentially of” or “consisting of” and remain within theexpressly defined scope of “comprising”.

“Providing” in a claim is defined to mean furnishing, supplying, makingavailable, or preparing something. The step may be performed by anyactor in the absence of express language in the claim to the contrary.

Optional or optionally means that the subsequently described event orcircumstances may or may not occur. The description includes instanceswhere the event or circumstance occurs and instances where it does notoccur.

Ranges may be expressed herein as from about one particular value,and/or to about another particular value. When such a range isexpressed, it is to be understood that another embodiment is from theone particular value and/or to the other particular value, along withall combinations within said range.

All references identified herein are each hereby incorporated byreference into this application in their entireties, as well as for thespecific information for which each is cited.

What is claimed is:
 1. A biogas upgrading system based upon PTSA and gasseparation membranes, comprising: a source of raw biogas comprisingmethane, CO₂, water, VOCs, and H₂S; a main compressor including asuction inlet in fluid communication with the source and receiving astream of raw biogas from the source; a PTSA unit comprising two or moreadsorbent beds each of which is selective for water, VOCs, and H₂S overCO₂ and for H₂S over methane, the PTSA unit being in downstream fluidcommunication with the main compressor and receiving a stream of a PTSAfeed gas therefrom, the PTSA unit being adapted and configured to adsorbwater, VOCs, and H₂S from the PTSA feed gas and produce a PTSA productgas deficient in water, VOCs, and H₂S in comparison to the PTSA feedgas; a first gas separation membrane stage comprising one or more gasseparation membranes selective for CO₂ and O₂ over methane, a feed gasinlet of the first gas separation membrane stage being in downstreamfluid communication with the PTSA unit, the first gas separationmembrane stage being configured and adapted to separate the PTSA productgas into a first stage permeate gas stream and a first stage retentategas stream; a second gas separation membrane stage comprising one ormore gas separation membranes selective for CO₂ and O₂ over methane, afeed gas inlet of the second gas separation membrane stage being indownstream fluid communication with the retentate outlet of the firstgas separation membrane stage and receiving the first stage permeate gasstream therefrom, the second gas separation membrane stage being adaptedand configured to separate the first retentate gas stream into a secondpermeate gas stream and a second retentate gas stream, wherein: the PTSAunit is in fluid communication with the permeate gas outlet of the firstgas separation membrane stages so as to receive a flow of the firststage permeate gas for use as a thermal regeneration gas to thermallyregenerate and desorb water, VOCs, and H₂S that was adsorbed upon theadsorbent beds from the PTSA feed gas stream; and the PTSA unit is influid communication with the permeate gas outlet of the second gasseparation membrane stage so as to receive a flow of the second permeategas stream for use as a cool down stream for cooling one or moreadsorbent beds after thermal regeneration thereof; and a treatment unitin downstream fluid communication with the PTSA unit so as to receive awaste gas from the PTSA comprised of the thermal regeneration gas andwater, VOCs, and H₂S, the treatment unit being adapted and configured toeither oxidize or burn the VOCs contained in the waste gas.
 2. Thesystem of claim 1, wherein the suction inlet of the main compressor isin fluid communication with the PTSA unit so as to receive the cool downgas stream from the PTSA unit and allow combination and compression withthe raw biogas stream.
 3. The system of claim 1, further comprising asecondary compressor including a suction inlet that is in fluidcommunication with the PTSA unit so as to receive the cool down gasstream from the PTSA, wherein the feed gas inlet of the first gasseparation membrane stage is in downstream fluid communication with anoutlet of the secondary compressor so as to receive the cool down gasstream after compression by the secondary compressor and separate acombined feed of the cool down gas stream and the PTSA product gas intothe first stage permeate gas stream and a first stage retentate gasstream.
 4. The system of claim 1, wherein the main compressor includesan oil cooling circuit including a heat exchanger adapted and configuredto exchange heat between the first stage permeate and oil flowing in thecooling circuit so as to heat the first stage permeate to thetemperature at which thermal regeneration of the adsorbent beds is totake place.
 5. The system of claim 1, further comprising a H₂S removalunit in flow communication between the main compressor and the PTSAunit, the H₂S removal unit being adapted and configured to removeamounts of H₂S present in the PTSA feed gas stream prior to feeding thePTSA feed gas stream to the PTSA unit, wherein the PTSA unit is adaptedand configured to remove amounts of water and VOCs from the PTSA feedgas stream and also amounts of the H₂S remaining in the PTSA feed gasstream after treatment by the H₂S removal unit.
 6. The system of claim1, further comprising a heat exchanger adapted and configured toexchange heat between hot gas from the treatment unit and theregeneration gas stream so as to heat the regeneration gas stream to thetemperature above the PTSA feed gas temperature.